Systems and methods for composite structures with embedded interconnects

ABSTRACT

A composite interconnect assembly includes a body structure formed from a composite material (e.g., a carbon graphite material) with one or more conductive traces embedded therein (e.g., a copper or copper alloy). One or more contact regions are provided such that the conductive traces are exposed and are configured to mechanically and electrically connect to one or more electronic components. The body structure may have a variety of shapes, including planar, cylindrical, conical, and the like.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent ApplicationSer. No. 61/230,559, filed Jul. 31, 2009.

TECHNICAL FIELD

The present invention generally relates to printed circuit boards andother interconnect structures used for mounting and connectingelectrical components.

BACKGROUND

Printed circuit boards (PCBs) are widely used many industries, andtypically consist of laminate structures with one or more levels ofmetallization or other conductors to interconnect the componentsattached to the board. Commonly known boards, however, areunsatisfactory in a number of respects.

For example, because standard PCBs do not exhibit significant structuralstrength and are prone to bending, torsion, and buckling, it istypically necessary to provide an additional rigid structure formounting to the PCB. This adds weight, manufacturing cost, andcomplexity.

Furthermore, standard PCBs, even in automated processes, often requiresignificant human handling. Such processes are time-consuming,expensive, and can significantly increase the amount of foreign objectdebris (FOD) that enters the system.

Finally, standard PCBs are generally planar, and thus for any givenmounting area they typically limit the range of enclosure shapes andsizes that a designer may employ.

Accordingly, it is desirable to provide improved interconnect structuresthat have structural strength, can be formed in a variety of shapes, andreduce human interaction during component mounting. Other desirablefeatures and characteristics of the present invention will becomeapparent from the subsequent detailed description and the appendedclaims, taken in conjunction with the accompanying drawings and theforegoing technical field and background.

SUMMARY

In accordance with one embodiment of the present invention, a compositeinterconnect assembly includes a body structure comprising a compositematerial (e.g., a carbon graphite material) with one or more conductivetraces embedded therein (e.g., a copper or copper alloy). One or morecontact regions are provided such that the conductive traces are exposedand are configured to mechanically and electrically connect to one ormore electronic components. The body structure may have a variety ofshapes, including planar, cylindrical, conical, and the like.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present invention may be derived byreferring to the detailed description and claims when considered inconjunction with the following figures, wherein like reference numbersrefer to similar elements throughout the figures.

FIG. 1 is a conceptual isometric view of a composite assembly inaccordance with one embodiment of the invention;

FIG. 2 is a conceptual isometric view of an alternate embodiment of thepresent invention; and

FIG. 3 is a cross-section of one embodiment of the present invention.

DETAILED DESCRIPTION

The following discussion generally relates to improved methods andapparatus for removing connectors from circuit card assemblies. In thatregard, the following detailed description is merely illustrative innature and is not intended to limit the invention or the application anduses of the invention. Furthermore, there is no intention to be bound byany expressed or implied theory presented in the preceding technicalfield, background, brief summary or the following detailed description.In the interest of brevity, conventionally known techniques andprinciples relating to composites, interconnects, and the like need notbe described herein.

Referring now to FIG. 1, in accordance with one embodiment of thepresent invention, a composite assembly 100 generally includeselectrical traces, interconnects, wires, or any other conductiveconnector 104 (collectively referred to as “traces”) incorporated,molded into, embedded, or otherwise formed within a composite materialstructure (or “body structure”) 102.

Holes, vias, contacts, or other contact structures 106 to whichcomponents can be mechanically and electrically connected are alsoprovided within body 102, and allow for contact to respective sectionsof traces 104. A variety of electronic components may be mounting tostructure 102, including microcontrollers, power semiconductors, or anyother electronic component now known or later developed.

The term “composite” as used herein with respect to body 102 generallyrefers to materials that are engineered from two or more constituentmaterials with significantly different physical or chemical propertiesthat remain separate and distinct on a macroscopic level. Such compositematerials include, for example, conventional carbon graphite materialsas well as any other suitable composite material now known or laterdeveloped, such as fiber-reinforced polymers (FRPs), metal matrixcomposites (MMC), cermets, and the like.

The material used for the electrical traces might include any suitableconductive material, including metals, semiconductors (e.g.,polysilicon), or the like. In a preferred embodiment, the tracescomprise a copper or copper alloy.

The composite assembly may be produced in a variety of ways. Forexample, body 102 may be formed around traces 104 (e.g., via molding).In another embodiment, traces 104 are inserted into or sandwichedbetween multiple layers of composite structures. In this regard, whilethe illustrated embodiments of FIGS. 1 and 2 depict a single layer ofconductive traces, the invention is not so limited, and may include anynumber of trace layers. FIG. 3, for example, shows a multiple tracelayers as well as multiple layers of composite structure 102 that aresuitably bonding together.

Traces 104 may be formed, for example, by common metal depositionmethods or masking operations, depending upon the nature of theconductor used. In an example embodiment, the traces 104 and relatedcontacts are designed a software tool, such as the Gerber PlottingSystem. Subsequently, conventional transfer methods are used to applythe traces, etching away any excess material.

Openings 106 may be configured to receive individual leads, flanges, orconductive bumps associated with the components to be attached, or maybe configured to allow components to be fully or partially recessedwithin a cavity within structure 104. In this way, the opening mayexpose sections of traces 104 that correspond to the configuration ofrespective leads on the mounted components.

The composite assembly may have a variety of shapes, including planar,circular, cylindrical, spherical, hemispherical, or any curvilinearmanifold structure. In one embodiment, for example, the compositeassembly is planar and has openings to receive electrical components.Leads from the electrical components project from one side of theassembly, and may then be soldered to the electrical traces via thedesired bonding method, (e.g., solder paste or metal alloy solders). Theprojecting leads may then be clipped in the conventional manner.

In an alternate embodiment, shown in FIG. 2, the assembly issubstantially in the shape of a tube (e.g., a hollow cylinder), in whichthe electrical components are inserted radially from the outer perimetertoward the interior (e.g., in holes or openings provided for thatpurpose). The components are then electrically connected and finished inany suitable manner.

The various composite structures of the present invention provide anumber of advantages over traditional PCB boards. For example, compositematerials are relatively strong and have a high yield strength. As aresult, it is not necessary to build a supporting rigid structure toaccompany it.

The thickness of the composite structure may be relatively low, giventhe structural integrity of the material used. That is, interconnectstructures can be made significantly thinner using this technology thanis the case with standard PCBs, e.g., less than about 1.5 mm.

Furthermore, as the structure can be formed in a number of shapes, itcan be inserted into tight spaces—e.g., typical conical or cylindricalenclosures common in missiles, rockets, and other aeronauticalstructures. In one embodiment, a DAC (divert attitude control) assemblyof the type used in connection with ballistic missiles, kill vehicles,and the like includes a composite assembly as described.

In addition, the electrical circuit can be validated before a missionhas started, eliminating hand soldering and FOD issues. Alignment,tolerances, and repeatability of the assembly are also enhanced.

While at least one example embodiment has been presented in theforegoing detailed description, it should be appreciated that a vastnumber of variations exist. It should also be appreciated that theexample embodiment or embodiments described herein are not intended tolimit the scope, applicability, or configuration of the invention in anyway. Rather, the foregoing detailed description will provide thoseskilled in the art with a convenient and edifying road map forimplementing the described embodiment or embodiments. It should beunderstood that various changes can be made in the function andarrangement of elements without departing from the scope of theinvention and the legal equivalents thereof.

1. A composite interconnect assembly comprising: a body structurecomprising a composite material; a conductive trace embedded within thebody structure; a contact region defined on the body structure such thatthe conductive trace is exposed and is configured to mechanically andelectrically connect to an external electronic component.
 2. Thecomposite interconnect assembly of claim 1, wherein the body isgenerally planar.
 3. The composite interconnect assembly of claim 2,wherein the body structure has a thickness of less than approximately1.5 mm.
 4. The composite interconnect assembly of claim 1, wherein thebody structure is generally tubular.
 5. The composite interconnectassembly of claim 1, wherein the composite material is a carbon graphitematerial.
 6. The composite interconnect assembly of claim 1, wherein theconductive trace comprises copper.
 7. The composite interconnectassembly of claim 1, wherein the contact region is an opening in thebody structure extending to the conductive trace.
 8. The compositeinterconnect assembly of claim 1, wherein the contact region is a bondpad substantially flush with the body structure.
 9. The compositeinterconnect assembly of claim 1, wherein the contact region is athrough-hole structure.
 10. The composite interconnect assembly of claim1, further comprising a plurality of conductive traces configured withinmultiple levels.
 11. The composite interconnect assembly of claim 1,wherein the body structure comprises at least two layers.
 12. A methodof making a composite interconnect assembly, comprising: forming a bodystructure comprising a composite material; embedding a conductive tracewithin the body structure; defining a contact region on the bodystructure such that the conductive trace is exposed and is configured tomechanically and electrically connect to an external electroniccomponent.
 13. The method of claim 12, including forming the bodygenerally planar.
 14. The method of claim 12, including forming the bodystructure such that it has a thickness of less than approximately 1.5mm.
 15. The method of claim 12, including forming the body structuregenerally tubular.
 16. The method of claim 12, wherein the compositematerial is a carbon graphite material.
 17. The method of claim 12,wherein the conductive trace comprises copper.
 18. The method of claim12, wherein the contact region is an opening in the body structureextending to the conductive trace.
 19. The method of claim 12, furtherincluding forming a plurality of conductive traces within multiplelevels of the body structure.
 20. A composite interconnect assemblycomprising: a body structure comprising a composite material having aplurality of levels; a plurality of conductive traces embedded withinthe plurality of levels; a plurality of contact regions defined on asurface of the body structure such that at least a portion of theplurality of conductive traces are exposed and are configured tomechanically and electrically connect to an external electroniccomponent.